Method for prefabricating glass block panels



Oct. 23, 1951 T. K; ALMRoTH ETAL METHOD FOR PREFABRICATING GLASS BLOCK PANELS Filed. Feb. 15, 1948 iatented ct. 23, .195i

:OFFI CE TMETHOD. FOR PREFABRICATINGA GLASS BLOCK PANELS Thomas vKirk Almrih and Thomas Kirk Almroth,Jr., Van Nuys, Calif.

`Application February 13, `194.8,.Serial N0.8,074

vThis invention relates .to the .fabrication of .glassr block panels of Vthe prefabricated .type .em-

bodying a plurality of .glass blocks .mounted within va iframe lof nailable .members such .as 2 x4 timbers. The general object of the present invention Vis to rprovide.improved methods for prefabricating suchpanels.

lThe prime vobject of the invention is to provide a method whereby glass .block panels may be fabricated with less expense than the expense involved in layingfa glassblockpanel atabuilding site. More particularly, the invention contemplates the prefabrication of .a .glass block panel ata factory and the transportation `of the complete panelasan .integralbuilding unit to a building site, where it maybe readily inserted by -a carpenter into a framedopening in. abuilding, eliminating thenecessityfor themasonto .make a return .trip to-a building. site long after he has performed the main masonry .work on the building. A substantial element in the prevailing high cost ofglass block panels insmall buildings is the matter of transportation of .the mason to and fromthe job to doa .piece of work which requires a relatively small amount of time in itself. `This is .true particularly in view `of the fact that itis notcustomary to embody large areas of glass block paneling in small buildings and homes, although va .considerable demand for relatively .small panels in homes and small vcommercial buildings .has developed. Another element .is the .high rate ycharged by the mason because of the relative unimportance of the job to him. Because y.of thehigh cost involved, there is a definite need for some means of providing such panels at. lower-expense, land it'is our object to vattainthisby prefabricating the panel away from the building site, .usingproduction methods in doing so.

An essential characteristieof the invention. is the utilization, as .part of the fabricatingapparatus, of a retaining frame which becomesa permanent'part of thepanel and which maybe secured in a building simply `by nailing itin place. The fabricating apparatusincludeain addition to such frame, a jig whichhasmeans for properly spacing Vthe glass blocks in the positionsthey areto occupy in the nishedpanel.

The jig, in addition to this functionof positioning the blocks, cooperates with the retaining frame to denne a mould in which the panel is cast. Thus the blocks maybe rstassembled on the jig, and the frame maythen'be applied to the, jig to form the mould.

Another object'is' to provide a method which V9 Claims. (Cl. 18459) leaves thepanel in iinishe'd condition immediately upon removal from the jig.

Accordingly, an object of theinvention is to provide a method whereby axglass block panel "embodying a peripheral retaining frame of nailable .material may be accurately prefabricated quickly .andinexpensively by simply associating therewith and with ithe V'blocks'to seal the spaces Other objects will becomeapparent inthe ensuing-:specifications and appended drawings in which:

l`Fig. 1 is a perspective view of a portion of a-jig Yembodied in your improved panel fabricating apparatus;

Fig. 2-is-`a plan View of such-ajig;

Fig. `3'is -a transverse sectional View through separated portions of a mould embodying the Ainvention;

Fig4'is a ltransverse sectional vvievv through portion's ofthe opposite side thereof.

Fig .5 is aperspective view of a portion of -a -jigf embodying-a modied form of the invention;

Fig. ."6 .is 4a view illustrating 'a series of the sealing'element which may be assembled to provide'. the: edge iportion'of the jig. shown in Fig. 5;

.i/Figf'isafplan view of'thej-ig of Fig. 5;

.fFig. 8 Iisadetaill sectional view of separated `portions voffa mould embodying the jig of Fig. 5, `illustrating agnumberof glass blocks assembled therein and illustrating the "application ofV the :bondingI agent 'between the blocks;

:Figs.29, g9a-and.9b vare agseries'of viewszofra 4tuck-.pointing tool for use in-,nishinga panel .madein the apparatusshown in Figs. 1 to 4 vor that shown in Figs. v5 to `8;

Fig. lois a transverse `sectional view of a portion `of a panel aftery ithasbeen tuck-pointed.

-In. Fig. 10 we have shown afragmentary sectionahviewy ofa glassblocl; panel constructed by the iisebf .the method and apparatus ofvour invention. Such v.panel comprisesa series of glass .blocks |5 mounted in a wocdenframe i6. The frame i6 is `constructedfrom vfour woodenbars .(e. g.2 X .4-s) nailed togetherat their endsas indicated at I1. VY.Each'of-.tlfiebarV 4me1nbers..of `the frar-neI- has in its-inner side,.alongitudinally extending .groove IS. l.'IT-l1e.=lolocks-l are uniformly .spaced from .eachA other .and `from .the

inner periphery of the frame IE, the spaces between the blocks being filled with layers of mortar I9 (Fig. 4) and the spaces between the outer sides of the blocks and the inner periphery of the frame I6 being filled with a peripheral layer 20 of mortar. Integral tongues 2| project from the outer sides of the peripheral layer 20 into the grooves I8 to form an interlocking connection with the frame IB.

In constructing a panel in accordance with the method illustrated in Figs. 1 to 4 inclusive, we employ a jig such as that indicated generally at 22 in Figs. 1 and 2. Such a jig comprises a peripheral frame 23, which may consist in four Wooden frame members nailed together at the corners of the frame; a supporting and reenforcing grid 24 comprising crossed members extending longitudinally and transversely between the ends and sides respectively of the frame 23, and a plate 25 supported upon and secured (as at 26) to the upper edges of the grid 24. The plate 25 is supported peripherally upon shoulders, 21 in the peripheral frame 22, formed by rabbeting the members of the frame as at 28.

The jig 22 is provided with crossed rows of' positioning or pilot pins 29, spaced so as to define a series of squares corresponding to the peripheral dimensions of the glass blocks I5. To be more specic,-the spacing of the pins 29 is such that the glass blocks will be snugly received between the several pins defining a particular square, and securely positioned in properly spacedY relationship, the thickness of the pins determining the Width of the spaces 3D (Fig. 3) between the blocks, into which mortar is inserted to form the mortar bonds I9. The outer rows of pins are positioned so as to be snugly received within the inner periphery of a frame I6, and thus determine the width of the peripheral space 3| in which the peripheral layer 2|] of mortar is cast.

In the casting of a panel, the frame I6 cooperates with the jig 22 to constitute a form or mould. The glass blocks I are arranged in the jig, the frame |6 is placed around the group of blocks and rested upon the upper faces of the frame 23, and sand 32 is then poured into the spaces 3U and 3|, filling those spaces to a height above the upper edges of thepins 29. The purpose of the sand is to hold back the mortar so that it will not enter the flaring outer extremities 33 of the spaces 3B and 3| adjacent the outer faces of the blocks. Preferably, the sand is inserted to a level slightly above the lower eX- tremities of the wider inner portions 34 of the spaces. 30 and 3|, so as to provide for retention of tuck-pointing mortar that is inserted in the spaces left by the removal of the sand after the panel has been cast. The reasons for building the level of the sand above the upper ends of the pins 29 are to avoid leaving any impression of pins in the mortar, and to protect the jig against becoming incrusted with mortar. Since the pins extend into the spaces 39 and 3| beyond the line occupied by the surface of the outer edges of the mortar in the finished panel, such depressions would occur if the sand were not used.

Mortar is then poured into the spaces 3U and 3|, to bond the blocks l5 to each other and to the frame I6 in an integral unit. 'Ihe mortar is prepared in a fairly liquid state so that it will readily fill all crevices in the spaces 30 and 3|. By employing a vibrator having a thin blade that will extend into the spaces 3|! and 3|, it is possible to employ a somewhat thicker slurry 4 and to settle it into the crevices between the blocks by vibration.

The mortar is poured to a height above the mortar nish line at the upper side of the block assembly, as indicated at 35 in Fig. 4. The excess mortar is then removed by a tuck-pointing tool such as the tool 36 shown in Fig. 9. This operation leaves the mortar joint with a finish edge such as that indicated at 3l in Fig. 4.

After the mortar has been fully poured and tuck-pointed on the upper face of the panel, the panel is allowed to rest, free of any vibration or disturbance, until the mortar has fully set. The panel is then lifted bodily from the jig 22, and is inverted on a flat, level supporting surface. The remaining sand in the now upper extremities of the spaces 30 and 3| is then cleaned out With a stiff brush, and mortar is poured into the spaces left by the removal of the sand, and is tuck-pointed in the same manner as on the other side of the panel. It will now be apparent that this tuck-pointing mortar will have enlarged flange portions occupying the extremities of the Wider portion of the spaces 34, and will thereby be securely held against dislodgement from the panel.

The panel thus formed constitutes an integral building unit having a frame I5 of nailable material. The mortar within the enlarged portions 34 of the spaces interlocks with the peripheral fianges 38 of the blocks, in the conventional manner, to securely retain the blocks in place in the panel.

The side extremities of the frame I6 lie in planes Hush with the outer corners of the flanges 38, with the rounded corners and the exposed faces of the blocks projecting beyond these planes so as to bring out to the fullest extent the beauty of design of the blocks. This is arranged for by having the supporting face of the plate 25 recessed below the edge faces of the frame 22, as indicated at 39 in Fig. 3.

It is contemplated that the frames I6 will be prefabricated in a mill and delivered in prefabricated form to the plant where the panels are cast. Prior to the casting process, the inner faces of the frame, including the groove I8, are coated with a sealing compound such as asphalt emulsion to seal the wood against penetration thereof by moisture from the mortar |9 prior to the time when the mortar becomes dry. This coating step may be performed at the casting plant, but it is preferably taken care of at the mill.

In the modied method employing the apparatus shown in Figs. 5 to 8 inclusive, we provide a jig 22a which eliminates the necessity for filling the lower extremities of the spaces 3U and 3| with sand. The jig 22a has means which may be employed in place of the pins 29 and sand 32, to locate the blocks and ll the lower regions of spaces 30, 3| for the initial mortar-pouring step, so as to leave channels which may later be lled with mortar and tuck pointed, or which may be utilized to provide finished mortar surfaces so as to eliminate the necessity for filling such channels with a second application of mortar, and subsequently tuck-pointing the same. This is accomplished by substituting for the positioning pins 29, a grid composed of a plurality of members A, B, C, D and E that are bonded to the upper faces of the frame and grid mem bers 23a and 24a respectively. The upper faces of the grid members 24a, instead of being recessed below the upper surfaces of the members f 51 23a. as in the form. shown in. Figs. 1' toz4. inclusive, are flush withA the upper surfaces of the form 22a and said upper surfaces are unrecessed. Consequently, the grid members A-E` lie in a common fiat plane.

The grid members A-E are of soft rubber or equivalent resilient material, andi each includes a flange portion 0 for adhesive attachment to the upper face of a corresponding frame member 23a or 24a, and a beaded portion #Ill which enters the lower extremity of a space 30er 31 asthe case may be so as to function as a positioning pilot. The outer faces of the glass blocks l rest upon the flanges 40 so as to form aseal between the blocks andv the grid structure, preventing any seepage of the mortar belowA the pilot beadsA lil. The pilot beads 41| may also be of such a thickness as to be slightly compressed by the edges of the blocks, so as to also have a sealing function. The extremities of the beads 41 are rounded so as to mold the edges of the mortar strips 2) with a characteristically tuck-pointed finish 3l. The mortar is simply poured into the spaces Sla and 30a, the excess mortar 35 being troweled away by the tuck-pointing tool 35. The panelv is then allowed to rest until the mortar has hardened, and the completed panel may then be simply lifted on the jig 22a, and is ready for use.

The grid member A is a straight strip that is secured to an upper face of a gridV member 25a. The grid member B is a straight strip of corresponding length that' is secured to the upper face of an outer frame member 23a.. It differs from the grid member A in that its outer flange 4U is thicker than its inner flange 4U, so as to make sealing engagement with the recessed under face of the frame I6. The sections B join the ends of the sections A to form the crossings of the grid structure. The sections D join the ends of the marginal sections B and form junctions with the sections A. The sections E join the sections B at the corners of the jig. The sections B and D have thickened flange members dii corresponding to the flanges 40 of the sections B and thinner anges 4Q corresponding to the thinner flanges v4l) of the sections A and B.

We claim:

1. A method of forming an integral block panel, including the following steps: providing a retaining frame, arranging blocks in predetermined order in said frame to provide spacing between the blocks, sealing off the lower extremities of said spaces, injecting a loose comminuted material into the lower regions of said spaces, inserting a bonding agent into said spaces above said comminuted material, subsequently unsealing the lower extremities of said spaces and removing said comminuted material, inverting the panel and inserting a bonding material into the spaces formerly occupied by said comminuted material.

2. A method of forming an integral block panel utilizing supporting means having upwardly projecting elements for spacing the blocks thereon, including the following steps:A Arranging the blocks on said supporting means with spaces between the blocks, into which said upwardly projecting elements extend so as to position the blocks, lling said spaces with loose comminuted material to a height such as to substantially cover the spacing elements, lling the spaces above said comminuted material with la bonding agent to bond the blocks into an integral panel, subsequently separating the panel from said supporting means and removing said comminuted material, inverting the panel, and in- 6 serting a bonding agent' into the-spaces. formerlyl occupied by the comminuted material.

3. A method of forming an integral'. glassr block panel comprising a series of blocks joinedt in spaced relationby a1 grid of bonding material, including the following steps: arranging the glassblocks on asupport having a plurality of upwardly projecting spacerelements, with spaces between the blocks into which said spacer elements extend, utilizing the engagement of! said spacer elements between said blocks to deter-f minethe desired spacing of the blocks, andthe engagement of the blocks with said supportingV means to close the lower extremities of said spaces, filling the lower areas of said spaces with a loose comminuted material to a sufficientheight to substantially cover the spacer elements, inserting into the spaces above said comminuted material, a bonding agent to bond the blocks into an integral panel, allowing the bonding agent to set, separating the panel from the supporting means and removing the comminuted material; inverting the panel, and inserting bonding agent into spacesv formerly occupied by the comminuted material.

4. A method of forming an integral glass block panel comprising a series of blocks joined in spaced relation by a grid of bonding material, including the following steps: arranging theY glass blocks on a support having a plurality of upward- 1y projecting spacer elements, with spaces between the blocks into which said spacer elements extend, utilizing the engagement of said spacer elements between said blocks to determinel the desired spacing of the blocks, and the engagement of the blocks with said supporting means to close the lower extremities of said spaces; nlling the lower areas of said spaces with a loose comminuted material to a sufiicient height to substantially cover the spacer elements, inserting into the spaces above said Icomminuted material, a bonding agent to bond the blocks into an integral panel, tuck-pointing the bonding material, allowing the bonding agent to set, separating the panel from the Supporting means and removing the comminuted material, inverting the panel, inserting bonding agent into spaces formerly occupied by the comminuted material, and' tuck-pointing the bonding material.

5. A method of prefabricating an integral Vglass block panel comprising a plurality ofl `blocks' joined in spaced relation by a grid of 'bonding material, including the following steps: arranging .the blocks upon a supporting means provided with upwardly projecting spacer elements with spaces between the blocks into which lsaiol spacer elements extend, utilizing the contact of the blocks with the spacer elements to space the blocks properly, inserting a bonding material into said spaces, allowing the bonding material to set so as to bind the blocks together into an integral panel, separating the panel from the spacer element, inverting the panel, and inserting a bonding material into the spaces formerly occupied by said spacer elements.

6. A method of preforming an integral glass panel comprising a peripheral frame and a plurality of blocks joined in spaced relation by a grid of bonding material, including the following steps: providing a supporting means having upwardly projecting spacer elements, supporting the frame loosely upon said supporting means, arranging the blocks upon said supporting means with spaces between adjacent blocks and between the outer blocks and said frame, with the said amaaisso spacer elements projecting upwardly into said spaces andfunctioning to position the blocks, inserting bonding material into said spaces to substantially the level of the upper faces of the blocks, tuck-pointing the bonding material at said upper faces, allowing the bonding material to set so as to bind the blocks together andr t said frame in an integral panel, separating the panel from said supporting means and inverting it, inserting additional bonding material into the spaces previously occupied by said Spacer elements, and tuck-pointing said additional bonding material.

7. A method of prefabricating an integral glass block panel comprising a plurality of blocks joined in spaced relation by a bonding material and a peripheral frame surrounding and secured to the outer blocks, including the following steps: positioning said blocks upon a supporting means with spaces therebetween, with removable means obstructing the lower portions of said spaces, supporting said frame upon said supporting means in a position surrounding the blocks, inserting bonding material into the unobstructed upper portions of the spaces between the blocks and the spaces between the blocks and frame, tuck-pointing said bonding material at the level of the upper faces of the blocks, allowing thel bonding material to set vso as to bind the blocks and frame together in an integral panel, inverting the panel and removing said obstructing means, inserting additional Abonding material into the formerly obstructed portions of said lspaces on the side which was formerly supported 4on said supporting means, and tuck-pointing said additional bonding material.

8. A method of prefabricating an integral glass block panel comprising a plurality of blocks joined in spaced relation by a bonding material and a peripheral frame surrounding and secured to the outer blocks, including the following steps: positioning said blocks upon a supporting means and inside said frame, with spaces defined between adjacent blocks and between-said frame and adjacent blocks, and with removable means obstructing the lower portions of said spaces, inserting bonding material into the unobstructed upper portions of said spaces to a level adjacent the upper faces of the blocks, :allowing the bonding material to set so as to bind the blocks and frame together in an integral panel, inverting thev panel and removing said obstructing means, and inserting additional bonding material into the formerly obstructed portions of said spaces on the side which was formerly supported on said supporting means, so as to complete the filling of said spaces.

9. A method of prefabricating an integral glass block panel comprising a plurality of blocks joined in spaced relation by a bonding material and a peripheral frame surrounding and secured to the outer blocks, including the following steps: supporting the frame immediately above the plane of a supporting means having a plurality of spacer strips projecting upwardly therefrom, including outer strips immediately adjacent the inner faces of said frame and a plurality of intermediate strips arranged within the confines of said outer strips in crossed relation, properly spaced to be received between blocks arranged in the desired relation to each other on said supporting means, arranging said blocks in said desired relation upon said supporting means with said strips extending upwardly between adjacent blocks and between said frame and the outer blocks, utilizingfsaid spacer strips for spacing said blocks and for obstructing the lower portions of said spaces, filling said spaces, above said obstructed lower portions thereof, with bonding material up to a level adjacent the plane of the upper faces of the blocks, allowing said bonding material to set so as to bind the blocks and frame together in an integral panel, lifting the panel off said supporting means and removing said spacing strips from said lower portions of said spaces, inverting the panel, and then filling the formerly obstructed portions of said spaces with bonding material to complete the filling of said spaces.

THOMAS KIRK ALMROTH. THOMAS KIRK ALMROTH, JR.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 1,082,231 Nale Dec. 23, 1913 1,092,195 Workman Apr. 7, 1914 1,137,297 Treo Apr. 27, 1915 1,546,493 Knipe July 21, 1925 1,795,862 Johnson Mar. 10, 1931 1,809,504 Carvel June 9, 1931 1,968,189 Bartels July 31, 1934 2,111,577 Thomas Mar. 22, 1938 

